US7086423B2 - Pile fabric - Google Patents
Pile fabric Download PDFInfo
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- US7086423B2 US7086423B2 US10/438,497 US43849703A US7086423B2 US 7086423 B2 US7086423 B2 US 7086423B2 US 43849703 A US43849703 A US 43849703A US 7086423 B2 US7086423 B2 US 7086423B2
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- 239000004744 fabric Substances 0.000 title claims abstract description 161
- 239000000835 fiber Substances 0.000 claims abstract description 63
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- 238000010438 heat treatment Methods 0.000 claims description 26
- 229920000728 polyester Polymers 0.000 claims description 19
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- 229920001155 polypropylene Polymers 0.000 claims 2
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Images
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/02—Pile fabrics or articles having similar surface features
- D04B21/04—Pile fabrics or articles having similar surface features characterised by thread material
Definitions
- the present invention is directed to a pile fabric of plush character adaptable for use in surface covering applications. More particularly, the invention relates to a pile fabric including an outwardly projecting pile portion formed from a multiplicity of multi-filament yarns.
- Pile fabrics such as velours, velvets, and the like are generally known. Such fabrics are typically formed using a sandwich method in which two fabrics are woven or knitted in face to face relation with the pile ends interlocking. A blade is used to slit through the pile ends to produce two separate pieces of fabric such that a multiplicity of yarns project outwardly away from the base so as to define a user contact surface.
- a common application for pile fabrics is in the covering of seating structures and other interior components for use within transportation vehicles including automobiles, trains, aircraft and the like. Such fabric is also typically used in the manufacture of standard furniture.
- the fabric in forming a pile fabric around portions of a seating structure, the fabric will be caused to bend around various sharp radius portions of the surface being covered. Such bending typically causes the pile-forming yarns to spread apart thereby exposing a portion of the underlying base fabric. That is, the bending causes a visually perceptive break in the surface coverage provided by the pile yarns. Such a break in surface coverage may be aesthetically displeasing and thus undesirable.
- Such textured yarns are subjected to processes such as false twisting and the like so as to impart a textured irregular surface character along the length of the filaments within the yarns so as to bulk the filaments along their length.
- processes such as false twisting and the like so as to impart a textured irregular surface character along the length of the filaments within the yarns so as to bulk the filaments along their length.
- the original substantially uniform character of the filaments within the yarns is substituted with an irregular random character.
- textured yarns may provide beneficial surface coverage characteristics, they may pose problems in fabric manufacture while also adding complexity and expense due to the texturizing processes required.
- use of such textured yarns may give rise to an enhanced potential for the occurrence of single end defects and nonuniformity in dyeing.
- the present invention provides advantages and alternatives over the prior art by providing a pile fabric such as may be used in automotive and furniture upholstery applications which fabric incorporates a pile surface formed from variable height pile-forming fibrous elements.
- the pile portion of the fabric is made up of a multiplicity of yarn tufts. At least a portion of the yarn tufts include a first group of pile-forming fibrous elements having a first height and at least a second group of pile-forming fibrous elements having a second height which is on average greater than the height of the first group.
- the height of the first group of pile-forming fibrous elements is at least about 25% less (and may be about 30%–45% less) than the height of pile-forming fibrous elements in the second group.
- the first (shorter) group of pile-forming fibrous elements defines a cooperative covering for the base of the pile fabric.
- the second (longer) group of pile-forming fibrous elements defines a dispersed upper contact surface imparting a soft feel to the user (i.e. low friction and high compressibility).
- the population density of pile-forming fibrous elements is characterized by at least two defined stages along the length of the tufts such that a first portion of the tufts adjacent the base of the fabric has a greater intra-tuft population density of pile-forming fibrous elements than the portion of the yarn tufts at the upper portion of the pile.
- the yarns making up the pile are preferably flat (i.e. untextured) yarns and may be characterized by a substantially uniform cross-sectional configuration along their length.
- the cross-sectional configuration may be round or some other appropriate yarn configuration such as a lobal wave cross-section or the like as will be well known to those of skill in the art.
- the tufts are also preferably substantially bloomed in a lateral direction. Such blooming reduces the void area between the tufts across the base thereby further improving surface coverage.
- FIG. 1 is a schematic illustrating an exemplary construction practice for formation of a pile fabric
- FIG. 2 illustrates a cut-away cross-section of a typical prior art pile fabric formed using flat (i.e. untextured) pile yarns;
- FIGS. 3A and 3B illustrate schematically a first practice for imparting variable shrink characteristics to a set of pile forming yarns
- FIGS. 4A and 4B illustrate schematically a second practice for imparting variable shrink characteristics to a set of pile forming yarns
- FIG. 5 is a cut-away illustration of an exemplary pile fabric in accordance with the present invention wherein the fibers within the pile are of variable height and bloomed to provide enhanced surface coverage across the base;
- FIG. 6 is a cross-sectional photomicrograph of a finished pile fabric wherein the fibers within the pile have a lobal wave cross section and are of variable height and bloomed to provide enhanced surface coverage across the base;
- FIG. 7 is a cross-sectional photomicrograph of a finished pile fabric wherein the fibers within the pile have a round cross section and are of variable height and bloomed to provide enhanced surface coverage across the base.
- FIG. 1 there is illustrated schematically a pile fabric formation apparatus 10 such as a double needle bar knitting machine as will be well known to those of skill in the art.
- a first pair of cooperating ground yarns 12 , 14 and a second pair of cooperating ground yarns 16 , 18 are delivered into opposing relation and are formed into a pair of opposing base or ground fabrics 20 , 22 .
- the first pile yarn 30 and a second pile yarn 32 are delivered to the fabric formation zone and are passed back and forth between the base fabrics 20 , 22 to form a sandwich structure 34 .
- the sandwich structure 34 is thereafter slit by a reciprocating or rotating blade element 36 so as to yield a pair of substantially identical pile fabrics 40 , 42 having free standing pile portions formed by the fibers of the first and second pile yarns 30 , 32 extending away from the base fabrics 20 , 22 .
- each of the pile fabrics 40 , 42 includes portions of both the first pile yarn 30 and the second pile yarn 32 .
- the fabric formation apparatus 10 is exemplary only in that virtually any other pile forming apparatus as may be known to those of skill in the art may likewise be used.
- other pile forming practices may include single needle bar knitting, velour weaving, tufting, stitch bonding, and the like.
- FIG. 2 there is illustrated a typical prior art pile fabric 40 formed from multi-filament flat (i.e. untextured) yarns.
- the pile fabric 40 includes a base fabric layer 20 formed by the cooperating ground yarns 12 , 14 and a outwardly projecting pile layer 50 formed by an arrangement of tufts 51 including the cooperating pile-forming fibrous elements of pile yarns 30 , 32 .
- the pile-forming fibrous elements forming the pile portion 50 are generally of a substantially equivalent height across the surface of the pile fabric 40 .
- it has been found that such prior fibrous elements typically have an average variation in height of less than about 20%.
- multi-filament yarn is formed from a multiplicity of discrete filaments which are combined together in a defined manner to yield a desired yarn construction having a predefined cross-sectional geometry and diameter.
- the individual filaments typically are formed from collections of long chain polymers which are expelled from a melt through a spinneret so as to impart only a partial degree of orientation to the molecular chains.
- the filaments (and the yarns formed therefrom) are only partially oriented in the longitudinal direction. Accordingly, such yarns typically are suitable for further longitudinal orientation by being passed through a yarn drawing operation.
- the present invention utilizes the ability to impart different characteristics to a yarn during drawing to yield at least two distinct sets of pile-forming fibrous elements for formation into a pile fabric.
- different levels of heat shrinkage potential are imparted to the pile-forming fibrous elements thereby causing one set of pile-forming fibrous elements to preferably shrink relative to another set of pile-forming fibrous elements when subjected to finishing and/or dyeing heat treatments.
- the pile forming fibrous elements which undergo shrinkage also bloom laterally outward so as to act substantially like self crimping fibers. This lateral blooming results in a substantially reduced void area between the tufts in comparison to standard pile products formed from flat yarns. Such reduced void area corresponds to enhanced surface coverage across the fabric base.
- a first exemplary procedure for applying variable heat shrinkage characteristics to pile forming yarns is illustrated through simultaneous reference to FIGS. 3A and 3B .
- a first sheet of pile yarns 130 is passed to a first draw zone 160 between a first set of nip rolls 162 and a second set of nip rolls 164 .
- a heater 163 is present in the first draw zone, such heater is preferably not activated.
- the second set of nip rolls 164 is operated at a faster speed than the first set of nip rolls 162 thereby tensioning the yarns 130 through the draw zone and causing further elongation and orientation of the yarns 130 .
- the draw zone 160 is not heated, thus the yarns 130 are referred to as a cold drawn yarn.
- the yarns 130 are thereafter passed through a heating zone 166 including a heater 165 between the second set of nip rolls 164 and a third set of nip rolls 168 .
- the third set of nip rolls 168 is operated at a slower speed than the second set of nip rolls 164 thereby giving rise to an over-feed condition in the heating zone 166 .
- the over-feed is preferably in the range of about 8% to about 30% and will most preferably be about 16%.
- the yarn Due to the over-feed condition at the heating zone 166 , the yarn is allowed to substantially relax thereby shortening to substantially the full degree permitted by the application of heat. That is, the yarn 130 is maintained for a time and at a temperature sufficient to constrict the yarn substantially to the full extent permitted such that upon application of subsequent high temperature environments, the yarn 130 does not shrink to a substantial additional degree.
- the heating zone 166 is maintained at a temperature sufficient to heat the yarn above its glass transition temperature (T g ).
- T g glass transition temperature
- the heating zone 166 is maintained at a temperature of about 215 Celsius and the dwell time of the yarns 130 within the heating zone 166 is preferably in the range of about 0.04 to about 0.1 seconds.
- the yarns 130 are thereafter delivered to a takeup 169 for subsequent incorporation into the pile of a fabric.
- a second sheet of yarns 132 which are substantially identical to the yarns 130 is passed through a draw zone 160 ′ between a first set of nip rolls 162 ′ and a second of nip rolls 164 ′.
- the second set of nip rolls 164 ′ is operated at a faster speed than the first set of nip rolls 162 ′ thereby causing a lengthening and further orientation of the yarns 132 . Since the draw zone 160 ′ is operated in an unheated condition with heater 163 ′ turned off, the yarns 132 are likewise considered cold drawn yarns.
- the pile yarns 132 are thereafter passed through a heating zone 166 ′ over heater 165 ′ between the second set of nip rolls 164 ′ and a third set of nip rolls 168 ′.
- the second set of nip rolls 164 ′ is operated at substantially the same speed as the third set of nip rolls 168 ′.
- the pile yarn is held in a substantially neutral tensioned state through the heating zone 166 ′.
- the heating zone 166 ′ is preferably operated at a temperature such that the yarn temperature is not elevated to a temperature above the glass transition temperature (T g ) for a prolonged period of time so as to relieve internal stresses within the yarn but without imparting substantial shrinkage. That is, while the yarn may be raised above the glass transition temperature for brief periods, it is generally held below this temperature.
- T g glass transition temperature
- the yarns 132 are not fully relaxed upon exiting the heating zone 166 ′ and therefore are susceptible to further shrinkage upon application of heat during subsequent processing.
- the yarns 132 are thereafter delivered to a takeup 169 ′ for subsequent incorporation into the pile of a fabric.
- FIGS. 4A and 4B an alternative process is illustrated wherein like elements to those previously described are designated by like reference numerals within a 200 series.
- the first sheet of pile yarns 230 is cold drawn across the draw zone 260 and is thereafter relaxed in an over-feed condition within the heating zone 266 exactly as in FIG. 3A .
- the second sheet of pile yarns 232 is treated differently.
- the first and second nip rolls 262 ′, 264 ′ are operated at substantially the same speed while the third set of nip rolls 268 ′ is operated at a higher speed.
- the yarns 232 are drawn to an extended length while in the heating zone 266 ′.
- the yarn 232 is thus considered a hot drawn yarn.
- the heating zone 266 ′ is preferably maintained at a temperature such that the yarn is generally maintained below its glass transition temperature (T g ) such that the yarn temperature is not elevated to a temperature above the glass transition temperature (T g ) for a prolonged period of time. That is, while the yarn may be raised above the glass transition temperature for brief periods, it is generally held below this temperature.
- T g glass transition temperature
- the yarns 132 are not fully relaxed upon exiting the heating zone 166 ′ and therefore are susceptible to further shrinkage upon application of heat during subsequent processing.
- the actual temperature of the heating zone may be above the glass transition temperature provided the dwell time of the yarn is such that the yarn itself does not exceed this temperature for prolonged periods.
- the pile yarns 230 upon exiting the heating zone 266 , the pile yarns 230 will be substantially fully shrunk and will not be susceptible to substantial further shrinking upon the application of heat. However, since the yarns 232 have not undergone relaxation, such yarns will be susceptible to heat shrinkage upon subsequent heat application.
- At least two groups of pile yarns with different shrinkage character are used in the formation of a pile fabric wherein one group of pile yarns is characterized by a retained residual shrinkage potential (i.e. the amount it can be further shrunk upon heat application) which is greater than the other yarn group.
- a retained residual shrinkage potential i.e. the amount it can be further shrunk upon heat application
- the difference in retained residual shrinkage potential between the two yarn groups is between about 3% and 40%.
- the yarn group with the lower shrinkage potential will be characterized by a retained residual shrinkage potential of about 3% or less and the yarn group with the higher shrinkage potential will be characterized by a retained residual shrinkage potential of about 6% to about 43%.
- differential shrinkage characteristics may be achieved by means other than drawing partially oriented yarns in different manners. Accordingly, by way of example only, it is contemplated that other yarns such as fully oriented yarns with variable shrinkage character may be used if desired.
- the pile yarns may be formed into a pile fabric using a suitable technique such as a double needle bar knit process described previously with respect to the prior art.
- each tuft within the pile portion of the fabric includes pile-forming fibrous elements from both high shrinkage and low shrinkage yarns.
- the pile fabric is thereafter passed through a standard tenter and/or other heat treatment apparatus such as a heated dye bath or the like wherein the formed fabric including the outwardly projecting pile-forming fibrous elements are subjected to an elevated temperature.
- this elevated temperature is preferably such that the pile is raised above its glass transition temperature to effect shrinkage of pile-forming fibrous elements from yarns with high retained shrinkage potential.
- a polyester pile fabric to a temperature of about 415 Fahrenheit for a period of about 2 minutes following formation permits the desired contraction of the high shrinkage pile yarns.
- the pile fabric 140 includes a base or ground fabric 120 and a pile portion 150 projecting away from the base fabric 120 .
- the pile portion 150 includes a multiplicity of pile forming tufts 151 each including a first grouping of pile-forming fibrous elements 180 and at least a second longer grouping of pile-forming fibrous elements 185 .
- the first grouping of pile-forming fibrous elements 180 is formed from yarn with high residual shrinkage potential such as yarn which was not fully heat shrunk prior to formation into the fabric construction 140 .
- the pile-forming fibrous elements 180 undergo contraction towards the ground fabric 120 and simultaneously bloom outwardly within the lower region of the pile portion 150 so as to close voids between the tufts.
- the longer pile-forming fibrous elements 185 are formed from yarns with relatively low residual shrinkage potential such as yarns which were substantially fully heat shrunk prior to formation into the fabric construction 140 .
- the pile-forming fibrous elements 185 do not undergo substantial further shrinkage.
- the shortened and bloomed pile-forming fibrous elements 180 serve to define a surface covering in the region immediately above the base fabric 120 .
- the pile-forming fibrous elements 185 which do not undergo substantial shrinkage during post formation heat treatment remain standing at an extended height above both the base fabric 120 as well as above the shortened and bloomed pile-forming fibrous elements.
- the tips of the pile-forming fibrous elements 185 projecting above the shortened pile-forming fibrous elements 180 thus define a contact surface of relatively dispersed yarn tips across the fabric construction 140 . Due to the relatively dispersed nature of the terminal ends of these yarns, they impart a soft feel to a user.
- the intra-tuft population density of pile-forming fibrous elements is substantially greater at the lower portion of the tufts than at the upper portion of the tufts.
- the change in intra-tuft fiber population density is substantially localized at the position along the tufts where the shorter fibrous elements 180 end. That is, the intra-tuft fiber population density along the length of the tufts from the base 120 to the outermost tips includes at least one localized step-wise decrease at a position below the tips corresponding to the termination of the shorter fibrous elements 180 . It has been found that in such a construction the yarns of the pile fabric perform in a cooperative manner wherein the shortened bloomed fibrous elements 180 provide the desired surface cover characteristics while the outstanding extended length fibrous elements 185 provide substantial tactile softness.
- the shorter bloomed fibers will preferably be on average at least about 25% shorter than the fibers in the taller group and will more preferably be on average at least 30%–45% shorter than the fibers in the taller group. Moreover, there is preferably about a 5% to about a 25% reduction in fiber population density along the tufts at locations more than about 75% along the tuft length above the base fabric. That is, the individual tufts preferably thin out by at least 5% to 25% in about the final 75% of their length.
- a 44 gauge double needle bar knit stitch fabric was formed in a sandwich structure at a six bar construction with ground yarns (forming the fabric base) carried in bars 1, 2, 5 and 6 and pile yarns carried in bars 3 and 4.
- the pile-forming yarns were characterized by variable shrinkage characteristics.
- the ground yarns carried in bars 1 and 6 were 100 denier 34 filament semi-dull round false twist textured polyester with post texturing entanglement.
- the ground yarns carried in bars 2 and 5 were 100 denier 36 filament spun drawn flat polyester yarns. Two different pile-forming yarns were used with each yarn being fully threaded through both bars 3 and 4 such that each pile tuft contains both pile-forming yarns.
- the first pile-forming yarn which was characterized by residual heat shrinkage potential of about 1 to 2 percent was a 160 denier 48 filament partially oriented full dull polyester yarn formed from filaments with a lobal wave shaped cross-section. This yarn was cold drawn followed by overfeed heated relaxation to 111 denier before fabric formation according to the process illustrated and described in relation to FIG. 3A above.
- the second pile forming yarn which was characterized by residual heat shrinkage potential of about 6 to about 8.5 percent was identical to the first pile-forming yarn but was drawn to 94 denier prior to fabric formation without overfeed heated relaxation according to the process illustrated and described in relation to FIG. 3B above.
- Formation and processing parameters for the fabric of this example are set forth in Table 1 below.
- a cross-sectional photomicrograph of the finished fabric is provide at FIG. 6 .
- the differential height of the pile filaments from the pile-forming yarn having high residual shrinkage relative to the pile filaments from the pile forming yarn having low residual shrinkage was measured by comparing the height difference between a number of pairs of randomly selected tall filaments from the yarn with low residual shrinkage and short filaments from the yarn with high residual shrinkage within the pile. This differential height between the tall fibers and the short fibers was found on average to be about 0.52 mm. The average height of the tall fibers defining the overall pile height was about 1.34 mm. Thus, on average, the fibers in the shorter group were about 39% shorter than the fibers in the taller group.
- a 44 gauge double needle bar knit stitch fabric was formed in a sandwich structure at a six bar construction with ground yarns (forming the fabric base) carried in bars 1, 2, 5 and 6 and pile yarns carried in bars 3 and 4.
- the pile-forming yarns were characterized by variable shrinkage characteristics.
- the ground yarns carried in bars 1 and 6 were 100 denier 34 filament semi-dull round false twist textured polyester with post texturing entanglement.
- the ground yarns carried in bars 2 and 5 were 100 denier 36 filament semi-dull round spun drawn flat polyester. Two pile-forming yarns were used such that each pile tuft contains both pile-forming yarns.
- the bar 3 yarn which was characterized by residual heat shrinkage potential of about 7 to about 8.5 percent was a 175 denier 48 filament partially oriented full dull round polyester yarn formed from filaments with a substantially circular cross-section and cold drawn to 100 denier before fabric formation according to the process illustrated and described in relation to FIG. 3B above.
- the bar 4 yarn which was characterized by residual heat shrinkage potential of about 1.2 to about 2.1 percent was identical to the bar 3 yarn but was cold drawn to 118 denier prior to fabric formation according to the process illustrated and described in relation to FIG. 3A above with overfeed of about 16 percent in the heating zone after drawing to effect shrinkage prior to fabric formation.
- Formation and processing parameters for the fabric of Example 2 are set forth in Table 2 below.
- a cross-sectional photomicrograph of the finished fabric is provide at FIG. 7 .
- the differential height of the pile filaments from the bar 3 pile-forming yarn having high residual shrinkage relative to the pile filaments from the bar 4 pile forming yarn having low residual shrinkage was measured by comparing the height difference between a number of pairs of randomly selected tall filaments from the bar 4 yarn and randomly selected short filaments from the bar 3 yarn. This differential height between tall fibers and short fibers was on average found to be about 0.48 mm. The average height of the tall fibers defining the overall pile height was about 1.34 mm. Thus, on average, the fibers in the shorter group were about 36% shorter than the fibers in the taller group.
- This fabric was formed identically to the fabric of Example 1 except that the pile-forming yarn of bars 3 and 4 was a 160 denier full dull wave polyester which was not drawn in the first zone and was hot drawn to 100 denier at 200 Celsius in the second zone of the drawing assembly so as to yield a yarn with about 4 to about 5.5 percent residual shrinkage capacity prior to fabric formation.
- the differential height of the pile filaments was measured by comparing the height difference between a number of pairs of randomly selected filaments within the pile. This average differential height was found to be about 0.25 mm. The overall pile height was about 1.34 mm. Thus, on average there was about 19 percent variability in tuft fiber height.
- This fabric was formed identically to the fabric of Example 1 except that the pile-forming yarn of bars 3 and 4 was a 160 denier full dull wave polyester which was cold drawn in the first zone to 100 denier and heat set at 200 Celsius in the second zone of the drawing assembly with no further drawing so as to yield a yarn with about 2.5 to about 3.5 percent residual shrinkage capacity prior to fabric formation.
- the differential height of the pile filaments was measured by comparing the height difference between a number of pairs of randomly selected filaments within the pile. This average differential height was found to be about 0.20 mm. The overall pile height was about 1.34 mm. Thus, on average there was about 15 percent variability in tuft fiber height.
- This fabric was formed identically to the fabric of Example 2 except that the fabric was heat set in sandwich form prior to slitting so as to replicate typical industrial formation practices for piece dyed double needle bar fabrics.
- the pile-forming yarn of bars 3 and 4 was a 175 denier full dull round polyester which was not drawn in the first zone of the drawing assembly and was hot drawn to 100 denier at 200 Celsius in the second zone of the drawing assembly so as to yield a yarn with about 4 to about 5.5 percent residual shrinkage capacity prior to fabric formation.
- the differential height of the pile filaments was measured by comparing the height difference between a number of pairs of randomly selected filaments within the pile. This average differential height was found to be about 0.07 mm thus indicating substantially no variability.
- This example illustrates construction parameters for an exemplary woven velour fabric according to the present invention. This construction was formed on a Van de Wiele weaving machine as will be known to those of skill in the art.
- ground warps and filling yarn were 2/150/34 semi-dull heptalobal false twist textured polyester.
- the warp 3 (pile-forming) yarn was a 2/150/48 full dull wave polyester.
- the warp 3 yarn was a 240 denier POY yarn which was not drawn in zone 1 but was hot drawn to 154 denier at a temperature such that the yarn remains generally below the glass transition temperature in the second zone.
- the drawn yarn leaving the second zone of the drawing apparatus was thereafter doubled through air entanglement jets to yield a yarn having a denier of 311.8.
- the warp 4 (pile forming) yarn was a 2/180/48 full dull wave polyester.
- the warp 4 yarn was a 240 denier POY yarn which was cold drawn to 150 denier in zone 1 and was overfed 16 percent at 215 Celsius in the second zone.
- the drawn warp 4 yarn leaving the second zone of the drawing apparatus was thereafter doubled through air entanglement jets to yield a yarn having a denier of 359.1.
- the weaving machine was threaded at 2 ends/dent in both pile and ground to get ends from warp 3 and warp 4 in the same tuft.
- such a woven velour fabric may be finished by slitting followed by brushing (i.e. napping), shearing and heat setting at 390 Fahrenheit with subsequent dyeing at 280 Fahrenheit followed by tenter drying with subsequent brushing and shearing.
- the finished fabric may be back coated by latex or the like.
- a 56 gauge clip kit construction was formed on a single bar rachel knitting machine set up to form a knitted (unfinished) fabric with 53 courses per inch.
- Bar 1 pile-forming yarn was a 115 denier yarn having 36 filaments of full dull polyester with round filament cross-section. Prior to fabric formation the bar 1 yarn was cold drawn from 115 denier to 74 denier in the first zone of a draw assembly as previously described and was heat set below the glass transition temperature in the second zone of the draw assembly with no additional drawing such that the yarn had a retained residual shrinkage capacity of 7.8 percent.
- Bar 2 pile-forming yarn was a 110 denier yarn having 48 filaments of full dull polyester with a lobal wave shaped filament cross-section. Prior to fabric formation, the bar 2 yarn was cold drawn from 110 denier to 70 denier in the first zone of a draw assembly as previously described. The cold drawn yarn was then overfed 16 percent at 215 Celsius in the second zone of the draw assembly such that the yarn had a retained residual shrinkage capacity of 1.57 percent.
- ground yarns (bar 3 and bar 4) were 115 denier yarn having 36 filaments of full dull polyester with round filament cross-section. Prior to fabric formation the ground yarns were hot drawn to 70 denier at 200 Celsius.
- the fabric was conveyed through a tenter (300 Fahrenheit) followed by pad drying (330 Fahrenheit), dyeing (280 Fahrenheit at 30 minutes), napping, heat setting (410 Fahrenheit) and shearing.
- the finished fabric had a mass per unit area of 13.5 ounces per square yard with 52.5 courses per inch and 37 wales per inch.
- Example 7 The procedures of Example 7 were repeated in all respects except that the pile was formed from a combination of yarn formed from filaments of wave-shaped cross-section with a retained residual shrinkage capacity of 6.2 percent and yarn formed from filaments of wave-shaped cross-section with a retained residual shrinkage capacity of 1.57 percent.
- the finished fabric had a mass per unit area of 13.1 ounces per square yard with 51 courses per inch and 37 wales per inch.
- Example 7 The procedures of Example 7 were repeated in all respects except that the pile was formed from a combination of yarn formed from filaments of round cross-section with a retained residual shrinkage capacity of 7.8 percent and yarn formed from filaments of round cross-section with a retained residual shrinkage capacity of 1.52 percent.
- the finished fabric had a mass per unit area of 14.4 ounces per square yard with 54.5 courses per inch and 37 wales per inch.
- Example 7 The procedures of Example 7 were repeated in all respects except that the pile was formed from a combination of yarn formed from filaments of wave shaped cross-section having a retained residual shrinkage capacity of 6.2 percent and yarn formed from filaments of round cross-section with a retained residual shrinkage capacity of 1.52 percent.
- the finished fabric had a mass per unit area of 13.7 ounces per square yard with 53 courses per inch and 37 wales per inch.
- Fabric samples were produced and prepared by cutting the edge with a razor to reveal the tufts in a coarse line.
- a video microscope (HIROX Hi-Scope Compact Micro Vision System Model KH-2200) was used to capture the image of the tufts of each fabric sample. Sample images were gathered at various locations to provide better statistical representation.
- Adobe PHOTOSHOP version 6.0 software photo images corresponding to 1 inch of fabric edge were transferred into IMAGE PRO PLUS version 4.5.029 software by Media Cybernetics.
- IMAGE PRO PLUS the void areas between the fabric tufts (as seen from the edge view) were traced and filled in with bright white for the image analyzer to pick out. The area of each filled in region between tufts was then calculated by the software. Ten files for each fabric sample were then averaged to yield an average void area between tufts.
- COMPRESSION ⁇ ⁇ RATIO 100 ⁇ ( T ⁇ ⁇ diff / T ⁇ ⁇ min ) Fabric ⁇ ⁇ Weight
- Tmin is the thickness as measured at application of a nominal baseline force of 0.5 grams force per square cm and Tdiff is the total thickness change during compression (mm) as measured between Tmin and application of a force of 50 grams force per square cm.
- fabric weight is divided out to eliminate variability based on weight.
Abstract
Description
TABLE 1 | |
Gap Setting | 4.0 mm |
Stitch Type | 6 Bar Knit Stitch |
Threading | Full Bar With an End From Bar 3 and |
Bar 4 Doubled in the Same Needle | |
Sandwich Thickness | 170 mm |
Courses Per Inch (At Slitter Exit) | 38 |
Wales Per Inch (At Slitter Exit) | 22.5 |
Greige Brush | Yes (3 brushes) |
Tenter Heat Set Temperature | 410 Fahrenheit |
Tenter Heat Set Dwell Time | 2 minutes |
Dyeing (After Heat Set) | Pressure Jet Dyed with Top |
Temperature of 280 Fahrenheit at 30 | |
minutes | |
Tenter Drying Temperature | 280–300 Fahrenheit |
Drying Brush | Yes |
Finish Brush | Yes (2 brushes) |
Finish IR Heat | Yes (250 Fahrenheit) |
Finish Steam | Yes |
Courses Per Inch (Finished Fabric) | 35 |
Wales Per Inch (Finished Fabric) | 23.5 |
TABLE 2 | |
Gap Setting | 4.0 mm |
Stitch Type | 6 Bar Knit Stitch |
Threading | Full Bar With an End From Bar 3 and |
Bar 4 Doubled in the Same Needle | |
Sandwich Thickness | 176 mm |
Courses Per Inch (At Slitter Exit) | 40 |
Greige Brush | Yes (3 brushes) |
Tenter Heat Set Temperature | 410 Fahrenheit |
Tenter Heat Set Dwell Time | 2 minutes |
Dyeing (After Heat Set) | Pressure Jet Dyed with Top |
Temperature of 280 Fahrenheit at 30 | |
minutes | |
Tenter Drying Temperature | 280–300 Fahrenheit |
Drying Brush | Yes |
Finish Brush | Yes (2 brushes) |
Finish IR Heat | Yes (250 Fahrenheit) |
Finish Steam | Yes |
Courses Per Inch (Finished Fabric) | 36 |
MIU=(miufor+miuback)/2.
As will be appreciated, by measuring friction in both directions variability due to pile orientation is eliminated.
Compression Evaluation:
Surface | Compression | ||
Sample | Void Area (mm2) | Friction | Ratio |
Example 1 | 0.01836 | 0.34 | 0.957 |
Example 2 | 0.05896 | 0.37 | 0.549 |
Example 3 | 0.03352 | 0.413 | 0.46 |
Example 4 | 0.0486 | 0.465 | 0.482 |
Example 5 | 0.2628 | 0.496 | 0.234 |
False twist textured | 0.02280 | 0.425 | 0.51 |
In one pile bar and hot | |||
warp draw yarn in the | |||
other pile bar | |||
False twist texture | 0.417 | 0.862 | |
yarn in both pile bars | |||
Example 7 | 0.040044 | 0.369 | 0.361 |
Example 8 | 0.02663 | 0.414 | 0.518 |
Example 9 | 0.040006 | 0.399 | 0.413 |
Example 10 | 0.050901 | 0.416 | 0.462 |
False twist textured | 0.017991 | 0.45 | 0.606 |
pile yarn (round) in | |||
combination with hot | |||
drawn wave filament | |||
yarn | |||
Claims (42)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/438,497 US7086423B2 (en) | 2003-05-15 | 2003-05-15 | Pile fabric |
PCT/US2004/012232 WO2004103055A2 (en) | 2003-05-15 | 2004-04-21 | Pile fabric |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/438,497 US7086423B2 (en) | 2003-05-15 | 2003-05-15 | Pile fabric |
Publications (2)
Publication Number | Publication Date |
---|---|
US20040244863A1 US20040244863A1 (en) | 2004-12-09 |
US7086423B2 true US7086423B2 (en) | 2006-08-08 |
Family
ID=33476574
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/438,497 Expired - Lifetime US7086423B2 (en) | 2003-05-15 | 2003-05-15 | Pile fabric |
Country Status (2)
Country | Link |
---|---|
US (1) | US7086423B2 (en) |
WO (1) | WO2004103055A2 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050003142A1 (en) * | 2003-07-03 | 2005-01-06 | Williamson Curtis Brian | Pile fabric, and heat modified fiber and related manufacturing process |
US20070006400A1 (en) * | 2005-07-05 | 2007-01-11 | Brown Robert S | Yarn and fabric with zones of varible heat set character |
US7481079B1 (en) | 2007-10-03 | 2009-01-27 | Milliken & Company | Circular knit fabric and method |
US7552604B1 (en) | 2008-04-09 | 2009-06-30 | Milliken & Company | Double needle bar elastomeric spacer knit |
WO2011103000A2 (en) | 2010-02-22 | 2011-08-25 | Milliken & Company | Fluid management system |
US20120255643A1 (en) * | 2011-04-08 | 2012-10-11 | Hongwei Duan | Fabrics having double layers of terry or pile |
US11492736B2 (en) * | 2018-04-13 | 2022-11-08 | Nike, Inc. | Knitted component with inlaid cushioning |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4343014B2 (en) * | 2004-04-13 | 2009-10-14 | 帝人ファイバー株式会社 | Dense ultrashort blanket, method for producing the same, and car seat member |
US20080010793A1 (en) * | 2006-07-03 | 2008-01-17 | Martin Wildeman | Textile fabric with variable heat-shrunk yarn constituents |
BE1023785B1 (en) * | 2016-01-15 | 2017-07-26 | Nv Michel Van De Wiele | METHOD FOR PRODUCING A TEXTILE PRODUCT |
Citations (10)
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US3241509A (en) * | 1963-04-30 | 1966-03-22 | Callaway Mills Co | Air blown tufted fabric |
US3999940A (en) * | 1975-01-02 | 1976-12-28 | Congoleum Corporation | Multicolored pile materials and processes for making the same |
US4600644A (en) | 1982-06-10 | 1986-07-15 | Monsanto Company | Polyester yarn, self-texturing in fabric form |
US5139725A (en) | 1982-12-17 | 1992-08-18 | Rhone-Poulenc Viscosuisse S.A. | Process for manufacture of crimped polyester yarn from cold drawn polyester-poy yarn |
US5501891A (en) * | 1994-04-28 | 1996-03-26 | Teijin Limited | Cushioning structure |
US5611127A (en) | 1992-08-06 | 1997-03-18 | Sorin Biomedica Cardio S.P.A. | Process for the manufacture of textile structures suitable for use in textile prostheses |
US5953783A (en) * | 1994-11-28 | 1999-09-21 | Hahn; Rainer | Material and implement for cleaning the surfaces of teeth and denture materials |
US5983470A (en) | 1998-06-26 | 1999-11-16 | Milliken & Company | Method to produce bulked deep dyed fabric |
US5997980A (en) * | 1997-02-20 | 1999-12-07 | Teijin Limited | Hollow polyester fibers and textile articles comprising same |
US6605332B2 (en) * | 1997-07-29 | 2003-08-12 | 3M Innovative Properties Company | Unitary polymer substrate having napped surface of frayed end microfibers |
-
2003
- 2003-05-15 US US10/438,497 patent/US7086423B2/en not_active Expired - Lifetime
-
2004
- 2004-04-21 WO PCT/US2004/012232 patent/WO2004103055A2/en active Application Filing
Patent Citations (10)
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US3241509A (en) * | 1963-04-30 | 1966-03-22 | Callaway Mills Co | Air blown tufted fabric |
US3999940A (en) * | 1975-01-02 | 1976-12-28 | Congoleum Corporation | Multicolored pile materials and processes for making the same |
US4600644A (en) | 1982-06-10 | 1986-07-15 | Monsanto Company | Polyester yarn, self-texturing in fabric form |
US5139725A (en) | 1982-12-17 | 1992-08-18 | Rhone-Poulenc Viscosuisse S.A. | Process for manufacture of crimped polyester yarn from cold drawn polyester-poy yarn |
US5611127A (en) | 1992-08-06 | 1997-03-18 | Sorin Biomedica Cardio S.P.A. | Process for the manufacture of textile structures suitable for use in textile prostheses |
US5501891A (en) * | 1994-04-28 | 1996-03-26 | Teijin Limited | Cushioning structure |
US5953783A (en) * | 1994-11-28 | 1999-09-21 | Hahn; Rainer | Material and implement for cleaning the surfaces of teeth and denture materials |
US5997980A (en) * | 1997-02-20 | 1999-12-07 | Teijin Limited | Hollow polyester fibers and textile articles comprising same |
US6605332B2 (en) * | 1997-07-29 | 2003-08-12 | 3M Innovative Properties Company | Unitary polymer substrate having napped surface of frayed end microfibers |
US5983470A (en) | 1998-06-26 | 1999-11-16 | Milliken & Company | Method to produce bulked deep dyed fabric |
Non-Patent Citations (2)
Title |
---|
Article "Crimping Fibers," pp. 24-30, Publication unknown. |
Article "The Kawabata System for the Standardization and Analysis of Hand Evaluation," Publication unknown. |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050003142A1 (en) * | 2003-07-03 | 2005-01-06 | Williamson Curtis Brian | Pile fabric, and heat modified fiber and related manufacturing process |
US20070006400A1 (en) * | 2005-07-05 | 2007-01-11 | Brown Robert S | Yarn and fabric with zones of varible heat set character |
US7674301B2 (en) | 2005-07-05 | 2010-03-09 | Robert Saul Brown | Yarn and fabric with zones of variable heat set character |
US7481079B1 (en) | 2007-10-03 | 2009-01-27 | Milliken & Company | Circular knit fabric and method |
US7552604B1 (en) | 2008-04-09 | 2009-06-30 | Milliken & Company | Double needle bar elastomeric spacer knit |
WO2011103000A2 (en) | 2010-02-22 | 2011-08-25 | Milliken & Company | Fluid management system |
US20120255643A1 (en) * | 2011-04-08 | 2012-10-11 | Hongwei Duan | Fabrics having double layers of terry or pile |
US8578972B2 (en) * | 2011-04-08 | 2013-11-12 | Hongwei Duan | Fabrics having double layers of terry or pile |
US11492736B2 (en) * | 2018-04-13 | 2022-11-08 | Nike, Inc. | Knitted component with inlaid cushioning |
Also Published As
Publication number | Publication date |
---|---|
US20040244863A1 (en) | 2004-12-09 |
WO2004103055A3 (en) | 2006-05-26 |
WO2004103055A2 (en) | 2004-12-02 |
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